Panel assembly and machine

ABSTRACT

A method and apparatus for making structural building units from a pair of spaced panels and interconnecting metal plates, the plates being inserted by means of powered plate inserting means and powered panel holding means wherein the plates are first positioned into recesses formed in the inner facing portions of the panels and then forced endwise into the panel. Also disclosed are various panel-joining plates having specially configured end portions to ensure positive holding action between the plates and panels.

United States Patent 9] Kay [451 Aug. 14, 1973 PANEL ASSEMBLY AND MACHINE [76] Inventor: Charles Kay, 6355 Thornapple River Dr., Alto, Mich. 49302 221 Filed: Aug. 13, 1971 211 Appl.No.: 171,564

[52] US. Cl 29/526, 100/D1G. 13, 227/26 [51] Int. Cl. 823p 19/00 [58] Field of Search 227/152, 26, 141,

[56] References Cited UNITED STATES PATENTS 4/1909 Farrington 227/26 5/1962 Kohl 29/526 2/1968 Rich 29/526 3,238,608 3/1966 Davis 29/526 Primary Examiner-Lowell A. Larson Attomey-Price, Heneveld, l-luizenga & Cooper [57] ABSTRACT A method and apparatus for making structural building units from a pair of spaced panels and interconnecting metal plates, the plates being inserted by means of powered plate inserting means and powered panel holding means wherein the plates are first positioned into recesses formed in the inner facing portions of the panels and then forced endwise into the panel.

Also disclosed are various panel-joining plates having specially configured end portions to ensure positive holding action between the plates and panels.

12 Claims, 17 Drawing Figures PAIENTEU mm 4 ma SMHIUFS FIG. 2.

PAIENTED 1 4 SHEEI 2 0f 5 FIG. 4.

memes mm m SHEEI '3 0f 5 FIG. (2..

' FIG. ll.

PAIENIE mm 4 ma SHEEI 5 BF 5 FIG. l5.

FIG. 17.

1 PANEL ASSEMBLYjAND MACHINE RELATED PATENTS AND APPLICATIONS This application relates to U. S. Pat. No. 3,286,428, application Ser. No. 800,620, filed Feb. 19, 1969, entitled CONSTRUCTION UNIT ASSEMBLY AND AP- PARATUS now US Pat. No. 3,574,253, and to application Ser. No. 125,707 filed Mar. 18, 1971, entitled BUILDING CONSTRUCTION ASSEMBLY now Pat. No. 3,714,696.

BACKGROUND OF THE INVENTION This invention relates to apparatus for making structural building units and more particularly, to a method and apparatus for inserting binder plates into and between a pair of spaced panels having aligned recessed portions therein on their facing surfaces.

Each of the above-identified patent applications disclose various methods and apparatus for inserting connecting plates into and between slabs and panels to thereby form structural building units. The specific structure disclosed in application Ser. No. 800,620 is particularly adaptable for inserting relatively short connector plates into board-sized slabs, e.g., relatively narrow in width in relation to their length. Application Ser. No. 125,707 is particularly adaptable to large panels, e.g., 4 feet by 8 feet, utilizing elongated metal connector plates extending substantially the full length or width of the panel, and discloses an elongated power insertion means for inserting the plates along the length of the panel. This latter structure forms an extremely strong and stable construction, but of course, requires an assembly machine at least two times the length of the panel to provide room for movement of the various components.

SUMMARY OF THE INVENTION An object of this invention is to provide a unique apparatus for forming structural building units from panels of substantial size, e.g., 4 feet by 8 feet, and relatively short connector plates, e.g., several inches in length.

In one embodiment of the invention, the metal spacer plates are positioned between panels at 90 to each other. Some of the plates may be provided with flanged ends while others of the plates may be provided with barbed ends forced into the panels in a separate operation.

The panels are provided with aligned recessed portions or slots along their facing surfaces. The plates are held in a holding and inserting fixture and as the panels are brought toward each other on each side of the holding fixture, the ends of the plates are positioned within the aligned slots or recesses. The plates are then advanced by a powered holding and inserting means in a direction parallel tothe panels, to insert these plates into the panels a distance at least equal to their length, thereby providing an integral connection between the two panels.

Another aspect of this invention provides a construction method and apparatus wherein the insertion means serves to hold a specially configured spacer plate at predetermined positions and the panels are moved toward each other, causing the plates to be forced into the panels at said predetermined positions.

The methods and apparatus disclosed enable quality building construction to be obtained readily and relatively inexpensively without the complex, costly steps required by conventional building techniques. The invention, therefore, fills a definite need in the construction of houses and similar buildings. These and other objects, advantages, and important aspects of the invention will become apparent from a study of the following description taken in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a plan view of the panel-holding and inserting apparatus of the present invention;

FIG. 2 is an end view of the apparatus taken along the plane "-1! of FIG. 1;

FIG. 3 is a perspective view of a building panel of the invention formed in the apparatus of FIGS. 1 and 2;

FIG. 4 is an end view of the panel shown in FIG. 3;

FIG. 5 is a perspective view of a connector plate utilized to interconnect a pair of panels;

FIG. 6 is a perspective view showing the connector plate of FIG. 6 in a final position holding a pair of panels together;

FIG. 7 is a view illustrating the plate member of FIG. 5 in a first position between a pair of panels prior to its final positioning as shown in FIG. 6;

FIG. 8 is a cross-sectional view taken along the plane VIII-VIII of FIG. 7;

FIG. 9 is a cross-sectional view taken along the plane IX-IX of FIG. 6;

FIG. 10 is a partial perspective view of a plate member having barbed end portions;

FIG. 11 is a partial sectional view illustrating a connecting plate of FIG. 10 in a panel;

FIGS. 12 and I3 illustrate the assembly of a pair of panels utilizing the connector plate shown in FIGS. 10 and 11;

FIG. 14 is a perspective view of a modified form of a connector plate having an integrally formed panel abutting ridge;

FIG. 15 is a side view of the connector plate shown in FIG. 14;

FIG. 16 illustrates a further modification of a connector plate; and

FIG. 17 shows the utilization of the connector plate 5 I v of FIG.16 to join a pair of abutting panels together.

Referring now specifically to the drawings and particularly to FIGS. l and 2, the apparatus 20 as illustrated includes a main support or base assembly 22, a movable plate retaining and inserting member 24 and a pair of pivotally mounted facing panel-holding beds or frames 26 and 28. The panel-holding beds 26 and 28 are pivotally mounted on either side of the insertion member 24 by means of shafts 30. The shafts are fixed at the lower portion of the beds, on either end and are suitably journaled in pillow blocks 32 fixed on the base 22. Movement of each of the beds 26 and 28 is accomplished by means of conventional hydraulic cylinders 34 pivotally connected at one end to the base 22. The other end of the cylinder has an extendable piston rod 35 pivotally connected to the bed in a conventional manner.

The consturction of each of the beds is essentially identical with the exception of a locking mechanism 36 carried on bed 26. As will be more fully described hereinafter, the locking mechanism 36 serves to hold the two beds 26 and 28 in a closed generally parallel position during plate inserting operations. In FIG. 2 a pair of panels P are shown positioned on each of the beds 26 and 28. Support rails 38 are provided at the lower end of each of the beds to position the panel in a first direction while a plurality of outwardly extending abutment means 40 are provided at one end of each bed to position the panels in a transverse direction and to prevent movement of the panel when the connector plates are forcibly inserted in a manner to be more fully described hereinafter. A plurality of rollers 42 may be positioned on the facing surfaces of each bed to facilitate loading of the individual panels thereon.

The plate-inserting mechanism 24 is movably mounted on the base 22 between the pivot beds 26 and 28 on a guideway or channel member 42. The guide way may be fixed to the base in any convenient manner such as, for example, by welding. One end of the inserting mechanism 24 is connected to the piston rod of a hydraulic cylinder 44. Insertion unit 24, under the actuation of cylinder 44, is then movable within the area defined by. the panel-supporting beds 26 and 28.

As illustrated, the insertion unit is comprised of several cooperative components. It has a movable vertical drive plate 46 which is secured at one end to the piston rod of cylinder 44. A plurality of upwardly extending perpendicular members 48 are provided to cooperatively support a plurality of connector plate-retaining jaws 50. The jaws are fixedly secured to the upright members and spaced slightly apart, just sufficient to allow the insertion of a connector plate C therebetween. These jaws keep the plates from deflecting or bending when the plates are forcibly advanced in the direction of the plane of the plates as described hereinafter.

Adjustment pads 52 are provided on the upright support members 48 and may be ,threadably received therein at their upper and lower extremities. The purpose of these pads is to control the relative spacing between opposing facing panel members when the beds 26 and 28 are raised to an upright and closed position. The pads abut the inner faces of the panels and may be adjusted by turning them in or out of the threaded portion of the upright members. Ideally, the adjustment pads are located in close proximity to the jaws 50 so that as the connector plates are inserted in the panels, the spacing between the panels is carefully held. It must also be noted that the supporting framework of the beds 26 and 28 include a plurality of cross members 54 which tend to rigidly hold the panel in the vicinity of the jaws so that as inserting operations are being performed there is no warping or bending of the panel.

Referring briefly to FIG. 5, the connector plate C which is utilized to connect the panels together in a spaced, parallel and aligned relationship is illustrated. Each connector plate is a generally rectangular-shaped member 56 having its side edges turned up substantially parallel to each other to form end flanges 58 and 60. The ends 62 of each flange may be beveled and slightly sharpened to aid in the insertion thereof.

OPERATION Referring now to FIGS. 3, 4, and 6 through 9, the operation of the apparatus and the construction of the panel will be described in detail. Referring first to FIGS. 3 and 4 a pair of panels P are seen held in a spaced-apart relationship by a plurality of connector plates C. Ideally, a substantial number of at least six equally spaced connector plates are utilized in each assembled panel for maximum support.

Prior to the insertion of the panels into the apparatus shown in FIGS. 1 and 2, each of the panels are provided with a plurality of recesses or pockets 64 arranged in a predetermined, aligned and spaced relationship. Ideally, each of the pockets are of a depth slightly less than one-half of the thickness of the panel and have a width and length slightly greater than the width and length of the flanges 58 and 60 on the connector plates.

A pair of panels provided with the above-described recesses are then positioned on the beds 26 and 28 as illustrated in FIG. 2. The lowermost edge of the panel abuts the guiderail 38 and the end portion is placed against the abutment 40 with the pockets 64 facing each other. Connector plates are then placed between each of the jaws 50 so that the flange of the lowermost jaw faces upwardly while the flanges on the upper jaws face downwardly. This, however, is optional so long as the corresponding recesses or pockets 64 in the panels are adapted to receive the plates in the desired orientation. The connector plates are inserted completely into the jaws until the leading edge makes fixed contact with the upright support member 48. The jaws may be electromagnetically actuated to hold the connector plates or small permanent magnets may be embedded in one or both of the facing surfaces of the jaws to prevent shifting of the connector plates. The hydrauilc cylinders 34 are then actuated causing the beds 26 and 28 with the panels supported thereon to move upwardly toward each other thereby assuming an upright vertical position generally parallel to each other on either side of the insertion mechanism 20. The facing portions of the panels contact the adjustment pads 52 slightly behind the recess 64 thereby maintaining a predetermined spaced relationship between each of the panels, an amount causing the flanged ends of the plates to extend into the recesses, i.e. part way into the thickness of the panels.

As the beds pivot together and assume a closed position, cylinders 36 on the bed 26 are actuated thereby driving its tapered piston rod 66 into a corresponding opening 68 provided inthe bed 28. This effectively locks the beds 26 and 28 together. After the beds have been locked together, cylinder 44 is actuated thereby causing movement of the insertion mechanism 20 along the length of the panels (to the right as viewed in FIG. 1).

As illustrated in FIGS. 7 and 8, the flanged ends of the connector plates are first positioned in the recesses 64 in the panels and, as the insertion mechanism moves, the beveled edges 62 of the connector plates are forced along the panel into the wood adjacent the recesses 64. When the full length of the plates are inserted into the panels, cylinder 44 is retracted, moving the jaws away from the connector plate and leaving the connector fixedly embedded in the wood between the panels, thereby securely holding the two panel sections together at a controlled spaced relationship.

Locking cylinders 36 are then released and cylinders 34 are retracted causing the beds 26 and 28 to open. The assembled panel is then positioned about the insertion mechanism 24 and may be removed by shifting it slightly forward and lifting it up and over the insertion mechanism in any convenient manner.

Depending upon the ultimate end use of the assembled panels, it may be desirable to provide additional bracing members C at right angles to those previously described. A plurality of such located members are shown in FIGS. 3 and 4 and may be inserted in a manner similar to that previously described, that is, by preliminary positioning of the cross braces within aligned recesses in the panel and then forcing them along the width rather than the length of the panel. Panels constructed in this fashion are particularly useful when used for floors, walls, roofs, and the like applications. The brackets placed at 90 to each other primarily serve to prevent racking of the panels.

The plates or brackets C' may alternately be inserted between the panels after the plates C have been inserted and the panel has been removed from the insertion apparatus. This may be accomplished by a separate operation utilizing an apparatus similar to that shown in my prior US. Pat. No. 3,574,253 which discloses a construction unit assembly wherein the panels may be slotted and the plates inserted through the slots. In either event, a panel assembly is provided having great resistance to racking. This is, of course, not a particular problem in wall constructions but is of great importance when the panels are utilized as flooring materials.

FIGS. through 16 disclose connector plates particularly useful for the construction of panels as above described. The plate shown in FIGS. 10 and l l is basically of flat, rectangular shape constructed of a relatively rigid material, preferably cold rolled steel. The ends of the plate are beveled as at 82 so as to be slightly wedgeshaped and provide a sharpened leading edge surface. The beveled edge is cut and folded back at one or more points along its surface to form a tab or barb 84. As indicated in FIG. 11, the end 82 of the connector plate may be forced into the wood and the tab 84 prevents it from being pulled out.

The assembly of a pair of panels with this connector plate is illustrated in FIGS. 12 and 13 wherein a plurality of connector plates 80 are each shown held between a pair of jaws 50' in a predetermined spaced relationship. The panels P are aligned and moved toward each other with sufficient pressure until such time as the panels contact the jaw members 50' to maintain a spaced relationship. As the panels move toward each other, the sharpened edge 82 of the connector plate 80 is forced into the panel. When the jaws are released, the panel and connector plates may be removed as an integral unit.

The apparatus shown in FIGS. 1 and 2 may be utilized for such an assembly operation with little. or no modification. Actually, all that is required is to place a pair of panels on the beds 26 and 28 as previously described. Brackets may then be placed in each of the jaw members 50 and the hydraulic cylinder. actuated to move the jaws and clamps to a forward position. Cylinders 34 are then actuated closing the beds thereby forcing the panels toward each other on either side of the insertion mechanism. As the ends of the plates are contacted by the panels they are gradually forced therein as the beds move upright to assume the vertical position. The beds 26 and 28 and cylinder 44 are then retracted and the panel is removed in the manner previ ously described.

The connector shown in FIGS. 14 and 15 is similarly provided with a plurality of barb members 84 along the edges which are inserted into the wood. The connector is further provided with ridges or stop members 86 which are spaced on the connector at a distance equal to the desired distance between the panels. The purpose of the ridge is to positively limit the entrance of the connector into the panel to a predetermined depth. This is accomplished when the ridge abuts against the face of the panel into which the connector is inserted. The connectors may similarly be applied by utilizing the mechanism shown in FIGS. 1 and 2 in the fashion as previously described in connection with the connector shown in FIG. 10.

Still another connector useful for joining a pair of panels together is illustrated in FIG. 16. As there illustrated, a plurality of rows of barb members 84 are provided on either end of the connector. The staggered relationship of the barbs with respect to the various rows provides for even greater holding ability. The connector shown in FIG. 16 is also useful for joining a pair of panels in abutting relationship as illustrated in FIG. 17.

It is conceivable that certain details of this construction may be modified in various ways within the concepts presented. It is intended, therefore, that the invention is to be limited only by the scope of the appended claims and the reasonably equivalent structures defined therein rather than to the specific details of the apparatus depicted as illustrative of the invention.

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows. v ll. Apparatus for making structural building units from a pair of spaced panels and a plurality of connector plates, said panels having a plurality of recesses formed therein in aligned relationship, said apparatus comprising:

a pair of panel supporting members;

panel alignment means on each of said supporting members; movable plate insertion means adapted to hold said plurality of connector plates in spaced relationship and in alignment with the receses in said panel;

means for moving said support members toward each other on each side of said plate insertion means so that said plates held therein extend into said recesses; and

power means connected to said insertion means to.

move said insertion means between said panels to thereby force said plates into said panels adjacent said recesses.

2. An apparatus as defined in claim 1 wherein said panel supporting members are pivotally mounted along one side thereof to be shiftable by said moving means between a first, divergent, panel receiving position and second closed position adjacent and generally parallel to each other.

3. An apparatus as defined in claim 2 and further comprising spacer means on said insertion means abutting said panels when said supporting members re moved to a closed position to maintain a predetermined spacial relationship between said panels.

d. An apparatus as defined in claim 3 and further comprising locking means on said supporting means for holding said supporting means in said closed position as said plates are forced into said panels.

5. An apparatus as defined in claim 4 wherein said insertion means includes a plurality of plate-engaging jaw members thereon-adapted to hold said plates in aligned position as said plates are forced into said panels.

6. An apparatus as defined in claim wherein said moving means and said power means comprise fluid cylinder means.

7. An apparatus as defined in claim 5 wherein said locking means comprises a fluid cylinder having a donwardly extending tapered piston rod mounted on one of said support members, said other of said support members having means thereon cooperable with said tapered piston.

8. Apparatus for making structural building units from a pair of spaced panels and a plurality of spaced connector plates comprising:

a pair of movable panel supporting members;

panel alignment means on each of said supporting members;

connector plate holding means positioned between said supporting members adapted to hold said plurality of connector plates in a predetermined spaced relationship between said panels; and power means operatively connected to said supporting members to move said members toward each other on each side of said plate holding means to thereby force said panels onto said plates, said panel-supporting members being pivotally mounted along one side thereof to be shiftable by said power means between a first, divergent, panel-receiving position and a second closed position adjacent and generally parallel to each other.

9. An apparatus as defined in claim 8 and further comprising spacer means on said plate-holding means abutting said panels when in a closed position to maintain a predetermined spacial relationship between said panels.

10. An apparatus as defined in claim 9 wherein said plate-holding member includes a plurality of plateengaging jaw members thereon adapted to hold said plates in aligned position.

1 1. An apparatus as defined in claim 10 wherein said power means comprises fluid cylinder means.

12. An apparatus as described in claim 1 wherein said connector plates are formed of a rigid material having a generally rectangular shape; and including a pair of upstanding parallel flange members on the ends thereof positioned in said recesses in said panels. 

1. Apparatus for making structural building units from a pair of spaced panels and a plurality of connector plates, said panels having a plurality of recesses formed therein in aligned relationship, said apparatus comprising: a pair of panel supporting members; panel alignment means on each of said supporting members; movable plate insertion means adapted to hold said plurality of connector plates in spaced relationship and in alignment with the receses in said panel; means for moving said support members toward each other on each side of said plate insertion means so that said plates held therein extend into said recesses; and power means connected to said insertion means to move said insertion means between said panels to thereby force said plates into said panels adjacent said recesses.
 2. An apparatus as defined in claim 1 wherein said panel supporting members are pivotally mounted along one side thereof to be shiftable by said moving means between a first, divergent, panel receiving position and second closed position adjacent and generally parallel to each other.
 3. An apparatus as defined in claim 2 and further comprising spacer means on said insertion means abutting said panels when said supporting members removed to a closed position to maintain a predetermined spacial relationship between said panels.
 4. An apparatus as defined in claim 3 and further comprising locking means on said supporting means for holding said supporting means in said closed position as said plates are forced into said panels.
 5. An apparatus as defined in claim 4 wherein said insertion means includes a plurality of plate-engaging jaw members thereon adapted to hold said plates in aligned position as said plates are forced into said panels.
 6. An apparatus as defined in claim 5 wherein said moving means and said power means comprise fluid cylinder means.
 7. An apparatus as defined in claim 5 wherein said locking means comprises a fluid cylinder having a donwardly extending tapered piston rod mounted on one of said support members, said other of said support members having means thereon cooperable with said tapered piston.
 8. Apparatus for making structural building units from a pair of spaced panels and a plurality of spaced connector plates comprising: a pair of movable panel supporting members; panel alignment means on each of said supporting members; connector plate holding means positioned between said supporting members adapted to hold said plurality of connector plates in a predetermined spaced relationship between said panels; and power means operatively connected to said supporting members to move said members toward each other on each side of said plate holding means to thereby force said panels onto said plates, said panel-supporting members being pivotally mounted along one side thereof to be shiftable by said power means between a first, divergent, panel-receiving position and a second closed position adjacent and generally parallel to each other.
 9. An apparatus as defined in claim 8 and further comprising spacer means on said plate-holding means abutting said panels when in a closed position to maintain a predetermined spacial relationship between said panels.
 10. An apparatus as defined in claim 9 wherein said plate-holding member includes a plurality of plate-engaging jaw members thereon adapted to hold said plates in aligned position.
 11. An apparatus as defined in claim 10 wherein said power means comprises fluid cylinder means.
 12. An apparatus as described in claim 1 wherein said connector plates are formed of a rigid material having a generally rectangular shape; and including a pair of upstanding parallel flange members on the ends thereof positioned in said recesses in said panels. 